Textile yarn finish

ABSTRACT

A TEXTILE FINISH COMPOSITION CONSISTING ESSENTIALLY OF A GLYCERYL TRIESTER, A SALT OF A SULFATED GLYCERYL TRIESTER, A WAX AND A SALT OF AN AROMATIZED PHOSPHATE ESTER HAVING THE FORMULA   (R(3-X)-PHENYL)-(O-CH-CH)N-O-P(=O)(-OH)X   WHEREIN N IS A NUMBER FROM 1 TO 10, R IS HYDROGEN OR AN ALKYL RADICAL OF UP 12 CARBON AND X IS ONE OR TWO.

United States Patent Olfice 3,594,200 Patented July 20, 1971 tion Ser. No. 583,111, Sept. 29, 1966. This application Nov. 28, 1967, Ser. N0. 686,320

1m. (:1. C0811 US. Cl. 106-245 1 Clam! ABSTRACT OF THE DISCLOSURE A textile finish composition consisting essentially of a glyceryl tn'ester, a salt of a sulfated glyceryl triester, a wax and a salt of an aromatized phosphate ester having the formula wherein n is a number from 1 to 10, .R is hydrogen or an alkyl radical of up to 12 carbon atoms and X is one or two.

BACKGROUND OF THE INVENTION This application is a continuation-in-part of our earlier application Ser. No. 583,111, filed Sept. 29, 1966.

It is known in the art to apply lubricating antistatic finish compositions to yarns in order to protect them from static generation and mechanical damage in their high-speed contact with various surfaces. These compositions, however, are generally not suitable for use in hightemperature processing because of their propensity to smoking or fuming and to the formation of harmful deposits. Furthermore, the composition must not be associated with factors leading to a decrease in yarn uniformity.

A primary objective of this invention is to provide a finish for synthetic, continuous-filament yarns suitable for high-temperature twisting processing.

Another objective of this invention is to provide a finish for synthetic, continuous-filament yarns suitable for highspeed and high-temperature twisting processing.

It is a further objective to provide a finish suitable for use on polyester false-twist texturing yarns.

Other objects will become apparent in the course of the following specification.

The present invention provides an improved yarn treating composition for the production of bulky yarns in a high-temperature process. By the use of this invention bulky yarns are obtained without the creation of a fume problem and without sacrificing strength and uniformity.

SUMMARY OF THE INVENTION The present invention is based in part on the surprising discovery that when the salts of a phosphate ester of an alcohol containing an aromatic group are mixed with selected lubricating components, compositions are obtained that are notably suitable for the high-speed production of synthetic yarns that are to be exposed to high temperatures.

In accordance with this invention there as provided finish compositions comprising a salt of an aromatized phosphate ester, a glyceryl triester, a salt of a sulfated glyceryl triester, and a wax.

DETAILED DESCRIPTION OF THE INVENTION Partial, aromatized phosphate esters are prepared by reacting phosphorous pentoxide with an alcohol containing an aromatic group such as a benzene ring in its molecule. Preferred aromatic alcohols are those prepared by condensing a phenol such as an alkyl substituted phenol and an alkylene oxide. The preferred phosphate esters have the formula wherein n is a number from 1 to 10, R is hydrogen or an alkyl radical of up to 12 carbon atoms and X is one or two. The corresponding salts are then prepared by neutralization with a suitable base. A preferred salt is the potassium salt of a mixture of aromatized phosphate esters where R is nonyl.

The glyceryl triester used in this invention is an ester of glycerol and one or more aliphatic acids. The triester may be a natural or synthetic material and is preferably of a high level of purity as contaminants tend to decrease thermal stability. The triester should be stable to temperatures of at least 150 C. and not cause obnoxious fumes or smoke. The glyceryl triester may be formed from fatty acids and preferably from saturated fatty acids having at least 12 to about 20 carbon atoms per molecule. Suitable glyceryl triesters include vegetable oils such as coconut oil, peanut oil, corn oil and synthetic esters such as glyceryl trilaurate, glyceryl tripalmitate, glyceryl dilaurate-palmitate and the like. A preferred triester is refined coconut oil.

The sulfated glyceryl triester employed in the composition is a neutralized reaction product of sulfuric acidwith a glyceryl triester containing aliphatic unsaturation and/ or a hydroxyl group. Suitable glyceryl triesters which may be sulfated are those formed from one or more unsaturated fatty acids such as oleic acid, linoleic acid, and the like. A suitable hydroxyl-containing fatty acid is ricinoleic acid. Preferred materials are sulfated glyceryl trioleate, sulfated peanut oil, and sulfated olive oil. The sulfated fatty esters are neutralized with a suitable base and used in the form of their salts which is preferably an alkali metal salt, e.g., a sodium salt.

The waxes of this invention are the natural or synthetic hydrocarbon Waxes. The Wax may be a paraflin wax, microcrystalline wax, Fischer-Tropsch wax, polyethylene wax and the like.

Preferably, the wax is a soft wax and, as such, may constitute an intimate mixture of wax with a mineral oil. The soft wax mixture will generally consist of about 35 to 40% oil and 60 to 65% of a hydrocarbon wax, and has a melting point below about 35 C. Both the oil and wax are predominantly naphthenic in character, i.e., the hydrocarbon molecules contain condensed aliphatic rings. The molecular weight of the naphthenic hydrocarbons in the oil-wax mixture ranges from about 600 to about 800 with the higher molecular weights being representative of the wax. Small amounts of other hydrocarbons, e.g., those characteristic of the higher viscosity lubricating oils may also be present. The mixtures useful in the practice of this invention do not form definitive crystalline patterns but maintain, at room temperature, an unctuous consistency. While any oil-wax mixture having the visual appearance of a pasty mass may be used, mixtures having a high proportion, e.g., 50 to by weight, of the wax constituent are preferred. A commercially available product of this character is TFO-8 of the Shell Oil Company, and is termed a bright stock soft-Wax.

The relative amounts of the ingredients used to prepare suitable, thermally-stable compositions may vary over wide ranges wherein the major portion will consist of the glyceryl triester and the sulfated glyceryl triester. The

proportions of the ingredients are advantageously within the following ranges, expressed as parts by weight: salt of aromatized phosphate ester, 10 to 40 parts, preferably 20 to 30 parts; glyceryl triester, 5 to 50 parts, preferably 15 to 30 parts; sulfated glyceryl triester, to 50 parts, preferably 30 to 40 parts; wax, 5 to 20 parts, preferably about 9 to about 13 parts. In addition to the above essential ingredients, small amounts of other materials may be added to the composition. For example, bactericides, buffering agents, tints, emulsification assistants, antioxidants and the like can be employed as circumstances may require.

These compositions may be applied directly to raw yarn or to previously coated yarn. The compositions are preferably used in the form of an aqueous emulsion in which the non-aqueous, or solids, content ranges from about 5 to 30%, preferably about 15 to 25%, by weight, based on the total weight of the emulsion. Application can be made by passing the yarn across the face of a rotating roll partially immersed in the emulsion. The concentration of the emulsion and the roll speed are such as to apply to the yarn from about 0.1 to about 1.5% solids, preferably about 0.2 to about 1.0% solids, by weight, based on the total weight of the treated yarn.

The emulsion can be applied prior to drawing, for example, following the convergence of quenched filaments below the spinneret. The finish may also be applied during drawing as in a draw bath, just after drawing, or at some other stage in the process.

In certain drawing procedures when the yarn is drawn by heating it with a high velocity fluid in a jet, a previously applied finish can be partially or essentially completely removed, thus requiring another finish application. Where reapplication is made over a previously applied finish having poor thermal properties, the finishes of this invention should constitute at least about half the weight of the total finish material present.

While the finishes of this invention may be used on synthetic yarns of polyamides, polyolefins and the like, they are particularly well suited to the manufacture of polyester yarns. Any of the polyesters may be used, but polyethylene terephthalate is preferred.

Finish compositions of this invention are particularly useful for the production of polyester, false-twist texturing yarns. The compositions perform well when applied to yarns travelling at speeds of 2,000 meters and more per minute, and they are stable at the temperatures used for twist setting, i.e., temperatures up to 250 C. and more. Thermal stability is exceptionally important in false-twist texturing, since, in addition to the formation of obnoxious fumes and deposit build-up, lubricity is lost and this contributes to poor yarn uniformity and to strength loss. Indeed, the lack of thermal stability in the finish can render such a process commercially inoperable. In addition, residues remaining after heating the composition of this invention are more fluid than those previously in use and, consequently, reduce the deposits that can occur on the texturing machine heating elements.

In producing continuous-filament yarns, it is desirable to provide the yarns with some twist, or a twist substitute, to give the bundle of filaments a unitary nature and thus facilitate handling and the like, such as removal from the package. In providing yarns for false-twist texturing, the yarns should contain a minimum of twist or interlace so as to provide the maximum in bulked yarn uniformity. The treated yarns of this invention are preferably interlaced to the extent that the distance between interlace nodes is about 40 centimeters. If the distance is greater than this, difiiculty is experienced in removing the yarn from the package. However, texturing performance of yarns containing little if any interlace is excellent. At relatively high interlace levels, e.g., 10 centimeters be tween nodes, textured yarn uniformity is adversely afiected.

In the following examples, for further'illustration of the invention, all parts are by weight and all percentages are by weight based on the total weight of the components.

EXAMPLE I A stainless-steel kettle is equipped with a mixer and a heating element. Into the kettle are placed 280 grams of refined coconut oil, 300 grams of the sodium salt of sulfated peanut oil and grams of a soft hydrocarbon wax. The soft hydrocarbon wax consists of an intimate blend of about 37% by weight of a high molecular weight naphthenic oil and about 63% by weight of a naphthenic wax and has a melting point of about 34 C. The molecular weight of the blend components ranges from about 600 to 800. The potassium salt of an aromatized phosphate ester is formed during emulsification by adding 250 grams of the acid ester to the mixture, warming with agitation to 60 C., and then adding the warm mixture to about 4040 grams of an aqueous solution of potassium hydroxide. The acid ester is prepared from an alcohol obtained by condensing one molecular proportion of nonyl phenol with about 5.5 molecular proportions of ethylene oxide and contains the monoand di-ester in a weight ratio of about 1 to 1. The potassium hydroxide solution contains 33.8 grams of potassium hydroxide, which amount is sufiicient to neutralize the ester and raise the pH of the emulsion to about 8, and it is heated to 60 C. before stirring in the heated mixture. The resulting emulsion, containing about 20% solids, is then allowed to cool to room temperature and is identified as emulsion A.

A polyethylene terephthalate textile yarn containing 34 filaments is drawn to a denier of 70 at 2882 meters per minute. The yarn has previously been treated with a composition prepared from butyl stearate, the sodium salt of sulfated peanut oil (containing about 23% water) and the product obtained by condensing 1 molecular proportion of cetyl alcohol with 17 molecular proportions of ethylene oxide in a weight ratio of about 5.0:1.5:1, and minor amounts, i.e., less than 1 part, of diethylene glycol, potassium hydroxide, oleic acid, triethanol amine and sodium o-phenylphenate. The yarn contains about 0.2% of the finish solids. Following drawing, emulsion A is roller applied so as to provide the yarn with 0.3% of the finish solids. The drawn and coated yarn is then led to a wind-up where it is packaged.

The yarn package is stocked to a false-twist texturing machine. The yarn is twisted to 31.5 turns per centimeter by overfeeding it to a false-twist spindle, rotating at 300,000 revolutions per minute, at a speed of meters per minute. The yarn is fed to the spindle at a rate 1.16 times that at which it is withdrawn. The twist is set by passing the twisted yarn over a metal plate 68.5 centimeters in length, heated to a temperature of 238 C. The process is easily operated as there are no start-up breaks and continuity of production is maintained with no difficulty. No noticeable fumes are produced during the heat setting and the yarn develops a high degree of mniform bulk with good strength retention.

EXAMPLE II A finish composition is prepared from 39.7 parts of the sodium salt of sulfated peanut oil, 24.3 parts of refined coconut oil, 2 parts of potassium hydroxide and 24.3 parts of the phosphate and 9.7 parts of the wax of Example I. The finish is prepared as described in Example I to provide an emulsion containing about 20% solids. The finish is applied to the same base yarn of, and as described in, Example I.

The yarn package thus obtained is stocked to a f lsetwist texturing machine. The yarn is twisted to 28.3 t rns per centimeter by overfeeding it to a false-twist spindle rotating at 300,000 revolutions per minute. The yarn is fed to the spindle at a rate 1.06 that at which it is with; drawn. The twist is set by passing the twisted yarn over metal plate 68.5 centimeters in length, heated to a temperature of 238 C. By using the technique of attaching a short length of a yarn having a low-friction, thermallyunstable finish for start-up, a high bulk yarn is readily obtained without any fumes or yarn strength loss.

EXAMPLE III A finish composition is prepared from 24.2 parts of coconut oil, 34.9 parts of the sodium salt of sulfated peanut oil, 2 parts of potassium hydroxide and 24.2 parts of the phosphate and 14.7 parts of the wax of Example I. Example II is then repeated to provide a package for false-twist texturing.

The yarn is twisted to 29.9 turns per centimeter by overfeeding it to a false-twist spindle rotating at 300,000 revolutions per minute. The yarn is fed to the spindle at a rate 1.04 times that at which it is withdrawn. The twist is set by passing the twisted yarn over a metal plate 68.5 centimeters in length, heated to a temperature of'238 C. The process runs with no difiiculty and a strong, bulky yarn is obtained without the production of fumes.

EXAMPLE IV A polyethylene terephthalate textile yarn is spun from a 34-hole spinneret, the filaments quenched and then passed over the face of a roll rotating in a 7% aqueous emulsion. The emulsion solids consist of a composition prepared from 49 parts of isocetyl stearate, 24.5 parts of sodium di(2-ethylhexyl)sulfosuccinate, 24.5 parts of the product obtained by condensing 1 molecular proportion of stearyl alcohol with 3 mols of ethylene oxide, 1 part of triethanol amine and 1 part of oleic acid. The treated yarn then passes to a high-temperature steam jet where it is drawn to a denier of 70. The drawn yarn contains about 0.2% of the composition. The drawn yarn is then treated with Emulsion A so as to provide the yarn with 0.4% of the composition solids. The yarn is false-twist textured and results similar to those of Example I are obtained.

EXAMPLE V A freshly-spun polyethylene terephthalate yarn is treated with a 10% aqueous emulsion of a composition prepared from 65 parts of isobutyl stearate, 10 parts of sodium di(2-ethylhexyl)sulfosuccinate, 6 parts of the product obtained by condensing 1 molecular proportion of nonylphenol with 5-6 molecular proportions of ethylene oxide, 6 parts of the product obtained by condensing 1 molecular proportion of a mixture of secondary aliphatic alcohols having from 11 to 15 carbon atoms with 3 molecular proportions of ethylene oxide, 11.7 parts of a mixture of the phosphate acid esters of the alcohol obtained from 1 molecular proportion of a mixture of secondary aliphatic alcohols having 12 to 15 carbon atoms with 3 molecular proportions of ethylene oxide and 1.3 parts of potassium hydroxide. The yarn contains 34 filaments and it is drawn in a high-temperature steam jet to a denier of 70. The drawn yarn contains about 0.2% of the composition solids. The drawn yarn is passed across the face of a roll rotating in Emulsion A and picks up 0.4% of the composition solids. The treated yarn is passed through an interlace jet and then the lightly interlaced yarn is wound up. The yarn is false-twist textured and a uniform bulky yarn with good strength retention is obtained.

What is claimed is:

1. A composition, for treating synthetic textile yarns to improve their processing characteristics, consisting essentially of about 27.5 parts by weight of coconut oil; 36.3 parts by weight of a sodium salt of sulfated peanut oil; 24.5 parts by weight of a potassium salt of an ester of the formula when n=about 6, R is nonyl, about A2 of this component having X: 1, the other half X=2; and 9.8 parts by weight of a soft hydrocarbon wax with a melting point of about 34 C.

References Cited UNITED STATES PATENTS 2,176,510 11/ 1939 Robinson 106-245 3,056,744 2/ 1962 Copes et al. 252-88 3,306,850 28/1967 Olsen 252--8.7 3,341,452 12/1967 Cooley 252--8.9

OTHER REFERENCES The Chemical Dictionary, p. 1090, 6th edition, 1961.

ALAN LIEBERMAN, Primary Examiner T. MORRIS, Assistant Examiner 

